Perforated Wire Wrapped Screen Support Rib

ABSTRACT

Embodiments of an apparatus of the present invention generally include a wire wrapped screen having a plurality support ribs, wherein at least one support rib comprises at least one orifice extending transversely there thorough. Additional embodiments of the present invention generally include an embodiment of a wire wrapped screen of the present invention disposed longitudinally circumferentially around a perforated pipe section. A method of providing and a method of utilizing embodiments of apparatuses of the present invention are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/508,192, filed on May 18, 2017, which application is incorporated herein by reference as if reproduced in full below.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The present invention relates generally to manufacture of wire screens for oil, gas, and water wells. More specifically, the present invention relates to a modified support rib used in the manufacture of wire wrapped screens.

BACKGROUND

Hydrocarbons are produced by drilling into subterranean hydrocarbon-bearing formations. Unconsolidated formation walls can result in sand, rock, or silt accumulating in a wellbore, which can ultimately cause various problems in the drilling operation. Sand control has become increasingly important in the industry.

Well screens (also called filters) used in sand control applications can be of various types, including wire mesh and continuous slot, wire wrapped. Continuous slot, wire wrapped screens are composed of wire helically wrapped around multiple support ribs to form a cylindrical screen with a continuous helical slot there between. Examples of such screens are disclosed in U.S. Pat. No. 2,046,459 to Johnson and U.S. Pat. No. 5,849,188 to Voll et al., both of which patents are incorporated herein by reference. The wire wrapped cylindrical screens are either formed directly on the exterior surface of sections of pipe, or are independently formed and slid onto sections of pipe. Once circumferentially disposed on the pipe section, the interior of the screen comprises a plurality of ribs extending longitudinally along the pipe section. Accordingly, a series of longitudinal channels between adjacent ribs makes up the annulus intermediate the pipe surface and the interior surface of the cylindrical screen.

In practice, the pipe within the cylindrical screen comprises one or more orifices (perforations) through the exterior surface thereof, so that fluid within the screen annulus may be introduced into the interior of the piping. A particular pipe surface orifice may be disposed within one or more adjacent channels, depending on width of the pipe orifice and the spacing between the ribs.

During downhole operations utilizing sand control screens, fluids containing entrained solids (sand) flow inward through the exterior of the cylindrical screen, whereby a majority of the particulate matter is filtered by the screen and substantially solids-free fluid is provided in the annulus. In some instances, however, solid particles are able to penetrate the screen and accumulate to form blockages in the channels. If a channel is blocked by such solids accumulation, fluid flow to the pipe orifices fluidly connected to that channel downstream of the blockage is prevented, which is undesirable. In addition, other circumstances or phenomena may cause uneven distribution of fluid to the screen and one or more channels may receive less or no fluid. It is therefore desirable to utilize a means of more assuredly providing even flow of fluid to all pipe orifices.

BRIEF SUMMARY OF THE INVENTION

Embodiments of an apparatus of the present invention generally comprise a wire support rib comprising a one or more orifices (perforations) extending transversely there through and disposed there along, whereby fluid communication through the rib is provided. In various embodiments, a rib may comprise regularly or irregularly spaced perforations and the rib perforations may comprise different geometries. Methods of providing and utilizing a wire screen comprising the perforated ribs are also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the exemplary embodiments, reference is now made to the following Description of Exemplary Embodiments of the Invention, taken in conjunction with the accompanying drawings, in which:

FIG. 1 depicts a partial cut-away view of a wire wrapped pipe utilizing a prior art rib design.

FIG. 2 depicts an isometric view of a prior art rib design.

FIG. 3A depicts an isometric view of an embodiment of a rib design of the present invention.

FIG. 3B depicts a side view of the embodiment of a rib design of the present invention shown in FIG. 3A.

FIG. 3C depicts a side view of an embodiment of a rib design of the present invention.

FIG. 4 depicts a partial cut-away view of a wire wrapped pipe utilizing an embodiment of a rib design of the present invention.

FIG. 5 depicts an embodiment of a filtration assembly utilizing an embodiment of a rib design of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The exemplary embodiments are best understood by referring to the drawings with like numerals being used for like and corresponding parts of the various drawings. Use of relative terms herein, such as “top,” “bottom,” “upper,” “lower,” “right,” “left,” “above,” “below,” and the like, are used for illustrative purposes only and are not intended to limit the invention to a disclosed orientation or arrangement. The term “pipe” is used herein interchangeably with the term “pipe section” and has the same meaning thereof.

FIG. 1 depicts a wire wrapped pipe utilizing a prior art rib design and comprising a pipe 2 containing a plurality of perforations 4 extending through the exterior surface 6 thereof. Fluid communication between the exterior of pipe 2 and the pipe interior 22 is provided by perforations 4. A plurality of substantially parallel, equally spaced ribs 8 are longitudinally disposed along the exterior surface 6 of pipe 2. A wire 10 is helically wrapped circumferentially around the rib 8 equipped pipe 2, wherein a gap (slit) 12 is provided between adjacent sections of the wire 10. Typically, the wire 10 is welded to a rib 8 at each point of contact (faying surface) 14 there between, thereby forming a wire wrapped screen 16. An annulus 18 is formed between the exterior surface 6 of pipe 2 and the interior surface of the wrapped wire (not separately labeled). Typically, prior art ribs 8 comprise one or more metals, such as carbon steel, stainless steel (e.g., 304L, 316L, 321, 347, 410, and 2205 duplex), nickel alloy 825 (Incoloy®), and alloy C276 (Hastelloy® C).

In the prior art example shown in FIG. 1, the ribs 8 form channels 20 within annulus 18. Typically, the bottom surface 26 (see FIG. 2) of a rib 8 is substantially contiguously in contact with exterior surface 6 of pipe 2, excluding any locations where a perforation 4 is disposed at least partially beneath the rib 8 (not shown). Accordingly, direct fluid communication between two adjacent channels 20 is not provided.

In one embodiment shown in FIG. 2, a prior art rib 8 comprises an elongated, substantially pentagonal member, although other geometries are employed. In one embodiment, rib 8 comprises a bottom end 28 and a top end 30. In the embodiment of FIG. 2, rib 8 comprises a horizontal, substantially planar bottom surface 26 flanked by two perpendicularly oriented, substantially planar vertical side surfaces 32. In this embodiment, two upper angled surfaces 34 extend from upper ends 36 of side surfaces 32 and converge proximate top end 30 of rib 8. In one embodiment, upper angled surfaces 34 converge to form a top exterior surface 38. In one aspect, a portion of exterior surface 38 of top end 30 of rib 8 provides one faying surface 14 when a wire 10 is welded to rib 8 to form a wire wrapped screen 16.

FIG. 3A depicts an isomeric view of an embodiment of a rib 8A of the present invention. In the embodiment of FIG. 3A, rib 8A, similarly to prior art rib 8, comprises a bottom end 28 and a top end 30, and a horizontal, substantially planar bottom surface 26 flanked by two perpendicularly oriented, substantially planar vertical side surfaces 32 wherein two upper angled surfaces 34 extend from upper ends 36 of side surfaces 32 and converge proximate top end 30 of rib 8. In one embodiment, upper angled surfaces 34 also similarly converge to form a top exterior surface 38.

In one embodiment, as depicted in FIG. 3A, rib 8A further comprises one or more orifices 24 extending axially (transversely) there through. In this embodiment, shown in greater detail in the side view of FIG. 3B, orifices 24 comprise a portion of the bottom end 28 of a rib 8, and thus extend through bottom surface 26 of rib 8A; i.e., said orifices comprise a substantially semi-circular geometry. In other embodiments, such as in the side view of a rib 8A depicted in FIG. 3C, one or more orifices 24 may extend solely through side surfaces 32 of rib 8A. In another embodiment (not shown) one or more orifices 24 may be disposed within at least a portion of one or both upper surface 34 of rib 8A. While the orifices 24 shown in FIGS. 3A-C are depicted as being oriented substantially transversely to rib 8A, i.e., substantially perpendicular with respect to the longitudinal axis of rib 8A, the invention is not so limited and other orientations may be employed. In another aspect, while the orifices shown in FIGS. 3A-C are depicted as being disposed substantially parallel to bottom surface 26, the invention is not so limited and other orientations may be employed. In addition, an orifice 24 may extend through bottom surface 26, one or both side surfaces 32, and one or both upper surface 34 of rib 8A.

Although the rib 8A orifices 24 shown in FIGS. 3A-C are depicted as comprising a rounded geometry, the invention is not so limited and orifices 24 may comprise any useful shape, as would be understood by one skilled in the art. In addition, orifices 24 of a rib 8A or of a plurality of ribs 8A may comprise different shapes. Orifices 24 of a rib 8A or of a plurality of ribs 8A having the same shape may comprise the same or different dimensions. Orifices 24 may be disposed along a rib 8A at regular intervals or may be irregularly spaced apart. Ribs 8A within a wire wrapped screen 16 may comprise the same number or a different number of orifices 24. An orifice 24 may have substantially uniform dimensions there through or may comprise varying dimensions there through. An orifice 24 may comprise one shape within a side surface 32 (and bottom surface 28 and/or upper surface 34) and comprise another shape within the opposite side surface 32 (and bottom surface 28 and/or upper surface 34).

Similarly to prior art ribs 8, ribs 8A may comprise one or more metals, such as but not limited to, carbon steel, stainless steel (e.g., 304L, 316L, 321, 347, 410, and 2205 duplex), nickel alloy 825 (Incoloy®), and alloy C276 (Hastelloy® C). In various embodiments, orifices 24 may be provided in a rib 8A by known means, such as by direct fabrication, machining, or drilling. Thus, a rib 8A comprising one or more orifices 24 may be fashioned by modifying a prior art rib 8, or it may be constructed directly. In addition, a directly constructed rib 8A comprising one or more orifices 24 may be further modified, such as by adding one or more additional orifices 24 and/or modifying one or more orifices 24 which the directly constructed rib 8A comprises.

FIG. 4 depicts a pipe equipped with a wire wrapped screen 16A which utilizes a plurality of ribs 8A. Wire wrapped screen 16A comprises components similar to wire wrapped screen 16 depicted in FIG. 1 and described above, with the difference being that one or more ribs 8A are used, in lieu of prior art ribs 8, to support wire 10. In the embodiment depicted in FIG. 4, ribs 8A comprise a plurality of orifices 24 extending axially (transversely) there through. In one aspect, orifices 24 allow direct fluid communication between adjacent channels 20 separated by a rib 8A which comprises the orifices 24. In one embodiment, shown in greater detail in FIGS. 3A and 3B, ribs 8A comprise one or more orifices 24 which comprise a portion of the bottom end 28 of the rib 8A, proximate the exterior surface 6 of pipe 2, thereby interrupting the substantially contiguous contact between the bottom surface 26 of that rib 8A and the exterior surface 6 of pipe 2.

In one embodiment (not shown) alternating ribs (i.e., every other rib) of a wire wrapped screen 16A comprise orifice(s) 24. In one embodiment, as shown in FIG. 4, ribs 8A are spaced such that ribs 8A (and therefore orifices 24) are not disposed directly above a pipe 2 perforation 4, while in other embodiments (not shown), ribs 8A may be provided such that one or more orifices 24 are disposed directly above a pipe 2 perforation 4.

Typically, to provide a wire wrapped screen 16A, a wire 10 is helically wrapped around a plurality of support ribs comprising one or more ribs 8A and, optionally, one or more prior art ribs 8. The invention is not so limited, however, and other manners of providing a wire wrapped screen 16A are contemplated. In one aspect, the ribs 8 of a completely (or partially) constructed wire wrapped screen 16 may be modified, as described above, to convert one or more of the ribs 8 into ribs 8A comprising one or more orifice 24. In another aspect, a completely (or partially) constructed wire wrapped screen 16A comprising one or more ribs 8A may be modified, as described above, to modify or add one or more orifices 24, and/or convert one or more of any ribs 8 into ribs 8A comprising one or more orifice 24.

FIG. 5 depicts a filtration assembly comprising a pipe 2 equipped with a wire wrapped screen 16A which utilizes a plurality of ribs 8A, such as shown in FIG. 4 and described above, and further comprising an outer mesh screen component 40 provided circumferentially about wire wrapped screen 16A, and a second outer wire wrapped screen 42 provided circumferentially about outer mesh screen component 40. While the embodiment shown in FIG. 5 depicts the outer wire wrapped screen 42 as comprising prior art ribs 8, in other embodiments (not shown), outer wire wrapped screen 42 may comprise one or more ribs 8A comprising one or more orifices 24.

While embodiments of ribs 8A of the present invention have been described in the context of supporting a helically wound wire screen component, the invention is not so limited and ribs 8A comprising one or more orifices 24 may be utilized on the exterior surface 6 of a perforated pipe 2 to support other types of screen components, such as a wire mesh filter. In addition, embodiments of ribs 8A of the present invention may be employed in other applications utilizing a wire wrapped (or other type) screen and a perforated pipe, wherein support ribs are disposed on a surface other than the exterior surface of the perforated pipe, such as but not limited to, cover filter support ribs disclosed in United States Patent Application Publication No. 2015/0238884 by Vu, which is incorporated herein by reference.

Operation

In one embodiment, a wire wrapped screen 16A comprising one or more ribs 8A is provided circumferentially exterior to a perforated pipe 2. In one aspect, such a wire wrapped screen 16A is formed, either directly circumferentially exteriorly onto a perforated pipe 2 or separately therefrom, such as in a manner described in United States Patent Application Publication No. 2015/0102014 by Everritt et al., which is incorporated herein by reference. If the wire wrapped screen 16A is not formed directly onto the pipe 2, it may be slid longitudinally circumferentially about the perforated pipe 2, as would be understood by one skilled in the art. Once the pipe 2 equipped with the wire wrapped screen 16A is provided, it may be utilized in a downhole drilling operation as any similar component comprising prior art ribs 8 would be.

In one aspect, during downhole operations utilizing a wire wrapped screen 16A, fluids (not shown) containing entrained solids (sand) (not shown) are allowed to flow inward through the exterior of the screen 16A, whereby fluid (and any solid particles not filtered out of the fluid by the screen 16A) is provided in the annulus 18. The fluid (and any unfiltered solids) flows within the channels 20. Fluid encountering a pipe 2 perforation 4 flows into the interior 22 of pipe 2. Fluid flowing within a channel 20 bordered by at least one rib 8A may flow through an orifice 24 into an adjacent channel 20. In one aspect, if a channel 20 bordered by at least one rib 8A becomes incapable of allowing fluid flow downstream of a certain location thereof, such as by solids pluggage, fluid in that channel 20 upstream of the pluggage can flow through one or more orifices 24 into an adjacent channel 20 (if the plugged channel 20 is bordered by only one rib 8A) or both adjacent channels 20 (if the plugged channel 20 is bordered by two ribs 8A).

Methods

In one embodiment, a method of providing a wire wrapped screen comprising one or more ribs 8A, each comprising one or more orifices 24, comprises the following steps:

A Wire Wrapped Screen Provision Step comprising providing a wire wrapped screen, such as wire wrapped screen 16A, comprising one or more support ribs, such as support ribs 8A, each comprising one or more orifices, such as orifices 24, extending transversely there through.

A Wire Wrapped Screen Equipped Pipe Provision Step comprising providing a pipe, such as pipe 2, comprising one or more perforations, such as perforations 4, in the exterior surface thereof, wherein disposed circumferentially exterior to the pipe is the wire wrapped screen.

In one embodiment, a method of utilizing a wire wrapped screen comprising one or more ribs 8A, each comprising one or more orifices 24, comprises the following steps:

A Wire Wrapped Screen Equipped Pipe Provision Step comprising providing to a downhole location a pipe, such as pipe 2, comprising one or more perforations, such as perforations 4, in the exterior surface thereof, wherein disposed circumferentially exterior to the pipe is a wire wrapped screen, such as wire wrapped screen 16A, comprising one or more support ribs, such as support ribs 8A, each comprising one or more orifices, such as orifices 24, extending transversely there through.

A Wire Wrapped Screen Equipped Pipe Operation Step comprising utilizing the downhole provided wire wrapped screen equipped pipe in a drilling operation.

The above described methods are merely exemplary, and additional embodiments thereof consistent with the teachings herein may be employed. In addition, in other embodiments, one or more of these steps may be combined, repeated, re-ordered, or deleted, and/or additional steps may be added.

While the preferred embodiments of the invention have been described and illustrated, modifications thereof can be made by one skilled in the art without departing from the teachings of the invention. Descriptions of embodiments are exemplary and not limiting. Disclosure of existing patents, publications, and known art are incorporated herein by reference to the extent required to provide details and understanding of the disclosure herein set forth. 

I claim:
 1. A wire wrapped screen comprising: a plurality of support ribs; and a wire; wherein: said support ribs comprise elongated components positioned substantially longitudinally parallel to each other to form a substantially tubular geometry; said wire is helically wrapped transversely around and welded to said support ribs at one or more points of contact there between; and at least one of said support ribs comprises one or more orifices extending transversely there thorough.
 2. The wire wrapped screen of claim 1, wherein at least one said support rib is substantially pentagonal in shape.
 3. The wire wrapped screen of claim 1, wherein at least one said orifice extends at least partially through a bottom surface of a support rib.
 4. The wire wrapped screen of claim 4, wherein at least one said orifice comprises a substantially semi-circular geometry.
 5. A piping filtration assembly, comprising: a pipe segment; and a wire wrapped screen; wherein: said pipe segment comprises a substantially tubular component comprising at least one perforation extending completely transversely through an exterior surface thereof; said wire wrapped screen comprises a substantially tubular structure comprising: a plurality of support ribs; and a wire; wherein: said support ribs comprise elongated components positioned substantially longitudinally parallel to each other to form a substantially tubular geometry; said wire is helically wrapped transversely around and welded to said support ribs at one or more points of contact there between; and at least one of said support ribs comprises one or more orifices extending transversely there thorough; and said wire wrapped screen is disposed circumferentially around at least a portion of said pipe segment.
 6. The piping filtration assembly of claim 5, wherein at least one said support rib is substantially pentagonal in shape.
 7. The piping filtration assembly of claim 5, wherein at least one said orifice extends at least partially through a bottom surface of a support rib.
 8. The piping filtration assembly of claim 5, wherein at least one said orifice comprises a substantially semi-circular geometry.
 9. The piping filtration assembly of claim 5, wherein at least a portion of at least one said support rib abuts said exterior surface of said pipe segment.
 10. The piping filtration assembly of claim 9, wherein said abutment extends longitudinally substantially contiguously along said pipe segment exterior surface, said abutment interrupted only by said rib support orifices.
 11. The piping filtration assembly of claim 5, comprising a filtration component disposed circumferentially around said wire wrapped screen.
 12. The piping filtration assembly of claim 11, wherein said filtration component comprises a wire mesh.
 13. A method of downhole filtration, comprising: providing the piping filtration assembly of claim 5; positioning said piping filtration assembly in a subsurface location; and utilizing said piping filtration assembly in a drilling operation.
 14. The method of claim 13, wherein at least one said support rib is substantially pentagonal in shape.
 15. The method of claim 13, wherein at least one said orifice extends at least partially through a bottom surface of a support rib.
 16. The method of claim 13, wherein at least one said orifice comprises a substantially semi-circular geometry.
 17. The method of claim 13, wherein at least a portion of at least one said support rib abuts said exterior surface of said pipe segment.
 18. The method of claim 17, wherein said abutment extends longitudinally substantially contiguously along said pipe segment exterior surface, said abutment interrupted only by said rib support orifices.
 19. The method of claim 13, wherein said piping filtration assembly comprises a filtration component disposed circumferentially around said wire wrapped screen.
 20. The method of claim 19, wherein said filtration component comprises a wire mesh. 